- 1). Lay the vintage window panes on a flat surface and place the pattern on top of the glass. Trace around each pattern piece with a pencil, scoring around the edge of the pattern piece with glass cutters. Vintage glass is old and should snap apart easily with your hands once it has been scored with the cutter. Make sure to wear heavy gloves to prevent cuts as you handle the glass.
- 2). Use the grinder to smooth the edge of each piece of glass. Set the pattern on your work surface and arrange the cut glass pieces as they are in the pattern. Number the pattern and the corresponding pieces to keep track of them and keep them in the right order.
- 3). Wrap the edge of each piece of glass with copper foil tape. Smooth the tape with your fingers to remove any air bubbles. The copper in the tape helps bond the glass pieces together when they are heated up. Most types of vintage glass are delicate and break easily, so don’t apply too much pressure while smoothing the tape.
- 4). Rearrange the pieces on your work surface and brush the foiled glass with flux. Flux is a chemical that removes oxidation from the foil and conducts heat to evenly distribute the solder. Use a soft paintbrush and brush it over the entire surface of the glass.
- 5). Plug in the soldering iron and allow it to heat up, and then solder the glass pieces together. Hold the soldering iron in one hand and the solder in the other, running the solder along the foil and into the spaces between the glass. Move slowly to allow the solder to completely fill in the gaps.
- 6). Turn the glass over carefully and solder the other side. Vintage glass is often thinner than more modern glass, so use caution when flipping it over. Solder the seams along the other side. Make sure that the solder completely overlaps the foil for a tight bond. Leave the piece to harden and cool overnight.
- 7). Dip a rag in patina solution and wipe it over the solder. Patina solution is a chemical that gives the fresh solder an antique feel that highlights the old vintage glass. Coat both sides of the solder with patina and allow it to dry before buffing with a dry rag. Clean the glass with glass cleaner to complete your new stained glass window.
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